Apparatus With an Exterior Surface Simulating a Natural Surface

ABSTRACT

An apparatus having an exterior surface that simulates a natural surface, comprising a polymer-foam sidewall having a concave first surface, a first end, and a second end. According to one embodiment in which the apparatus is a hunting blind, the sidewall is generally cylindrical and further has an inner surface, and defines a plurality of windows extending between the inner and outer surfaces. A first endwall is adjacent to the first end of the sidewall. A second endwall is adjacent to the second end of the sidewall. The sidewall, first end wall, and second endwall define an interior space that may be occupied by a hunter.

CROSS-REFERENCES TO RELATED APPLICATIONS

This divisional application claims the benefit of and priority to U.S.patent application Ser. No. 13/966,170, filed Aug. 13, 2013, whichclaims the benefit of and priority to U.S. Provisional Application Ser.No. 61/682,554, filed Aug. 13, 2012. Both of these prior filedapplications are incorporated by reference.

STATEMENT REGARDING FEDERALLY-SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to apparatuses for outdoor use and havingat least one surface designed to simulate the appearance of a naturalsurface, such as a vegetation surface or rock surface.

2. Background of the Art.

In hunting, game are adept at identifying unnatural (e.g., human) motionand sounds, as well as unnatural structures in their environment. Onetechnique used by hunters to counter game's ability to identifyunnatural motion and sounds is to use a hunting blind, which is a coverdevice designed to reduce the chance of detection.

Hunting blinds come in two main varieties. Elevated blinds arepositioned above ground, such as within a tree or on a stand. Groundblinds, on the other hand, sit directly on the ground.

Typical ground blinds often require a great deal of preparation andpatience prior to use. Because game such as deer are cautious andunaccepting of new and unfamiliar structures, a ground blind might haveto be left in the desired hunting location for extended time periodsprior to use. In addition, the blind may need to be “brushed in”—thatis, brush from the surrounding area gathered to place around the blindso the game does not see the unnatural outline. Not only can this take asignificant amount of time, but it must be done frequently, as thefoliage on the brush that provides the concealment dies off over timeand reduces the amount of cover.

Several devices have been developed to attempt to address theseproblems. For example, a blind sold under the trademark GHOSTBLIND®, byGhostBlind Industries of Marietta, Ohio, comprises a set of adjacentmirrors that are angled downward toward the ground surface. Thus, thenatural appearance of the surrounding ground surface is reflected by themirrors to the nearby game.

The GHOSTBLIND® blind, however, has several drawbacks. For one, themirrors are relatively fragile, and cannot be left unattended forextended periods of time without risk of damage. Second, the blind isrelatively small, is open to the environment and elements, and does notinclude aspects for inhibiting the transmission of unnatural sounds andscents. Third, there still remains risk of an unnatural imageinadvertently being reflected by one or more misaligned mirrored panels.

Other proposed solutions were arrived at by assignee of this applicationand are disclosed in U.S. Pat. Nos. D642,700, D652,343, D642,699, andD661,404. For example, U.S. Pat. No. D642,699 discloses a tree-likeobservation blind that has the general shape of a tree trunk. Thispatent, however, does not simulate a vegetation surface, but rathersimply the general outline and shape of a tree. In fact, the designdisclosed in U.S. Pat. No. D642,699 was determined to be inadequate,which resulted in development of the inventions disclosed and claimedherein.

SUMMARY OF THE INVENTION

The present invention relates to an apparatus having an exterior surfacesimulating characteristics of a natural surface, such as the bark of thetree. The apparatus comprises a polymer foam wall having a first end anda second end.

According to one embodiment, the sidewall has an outer surfacesimulating a vegetation surface, such as the bark on the trunk of atree. The sidewall further has an inner surface, and defines a pluralityof windows extending between the inner and outer surfaces. A firstendwall is adjacent to the first end of the sidewall. A second endwallis adjacent to the second end of the sidewall. The sidewall, firstendwall, and second endwall define an interior space that may beoccupied by a hunter.

In arriving at the present invention, one problem that was addressed wasthe sheer detail and scope of the subject molded articles. Moldingprocesses that may be similar to those described herein have been usedin other areas, such as the field of special effects make-up.

There are, however, fundamental differences between using the techniquefor special effects and in the simulation of natural surfaces.

For example, traditional molding techniques require utilizing anenclosure into which a curable mixture is poured and allowed to set.With the present invention, however, the scale of the potential subjectmatter—i.e., full-size trees—generally prevents the efficient use ofsuch enclosures.

In addition, traditional molding techniques are focused on accuracy anddetail of the mold at the expense of speed and manufacturing efficiency.While in the present application accuracy is important, the degree ofaccuracy need not be as precise as in, for example, the special effectsindustry. Rather, the ability to manage and handle the mold during themanufacturing process is prioritized over the precision required withother areas where silicone molding is required.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top isometric view of an embodiment of the presentinvention.

FIG. 2 depicts a sectional view through section line 2-2 of FIG. 1.

FIG. 2A is an enlarged view of window 2A of FIG. 2.

FIGS. 3A & 3B show a window assembly of the embodiment described withreference to FIG. 2 in a substantially open and a substantially closedstate, respectively.

FIGS. 4-8 show various stages of one embodiment being manufacturedaccording to the method of manufacture of the present invention.

FIG. 9 is a front elevation of an alternative embodiment of the presentinvention.

DESCRIPTION OF ONE OR MORE EMBODIMENTS OF THE INVENTION

FIG. 1 shows an embodiment of the present invention, which embodiment isa hunting blind 20 that simulates the textures and colors of a subjecttree's bark and is manufactured according the steps of the methoddisclosed herein. The blind 20 comprises a generally trunk-shapedsidewall 22 having an exterior surface 24 that imitates the texture ofnatural tree bark. This texture may include bare areas 26 that aresmooth, such as are frequently found in nature. Such natural texturesand shapes generally do not comprise straight lines and right angles.Although the blind 20 is shown as having the bark of an oak tree, anynumber of different trees may be simulated using the process describedherein. The exterior surface 24 of the sidewall 22 is coated with UVprotective paint selected to imitate the colors of the bark of thesubject tree. One such suitable paint is an exterior latex flat paint,C1 Series, sold under the tradename DURACRAFT by The Sherwin WilliamsCorporation of Cleveland, Ohio.

The trunk-shaped sidewall 22 includes a first end 28 and a second end30. In the preferred embodiment as intended to be used, the first end 28is positioned proximal to a ground surface 32 and is flared to simulatethe root flare of a natural tree. The second end 30 is positioneddistally from the ground surface 32. Windows 34 are disposed through thesidewall 22 to provide six viewports that are generally spacedequidistantly around the sidewall 22 to provide for generally athree-hundred sixty degree viewing angle. Preferably, the windows 34 areirregularly shaped so as not to use straight lines or right angles.

A door opening 37 extends through the sidewall 22 to provide access tothe interior of the blind 20. A door 39 is fastened to the sidewall 22and is rotatable to and from a closed position which it occupies in thedoor opening 37.

A first endwall 35 is positioned at the first end 28 of the sidewall 22.A second endwall 36 is positioned at the second end 30 of the sidewall22. The second endwall 36 has a convex exterior surface 38 that directsliquids (e.g., rainwater) toward channels 40 spaced around the convexsurface 38 and through the sidewall 22, which allow liquid to passthrough the sidewall 22 and fall to the surrounding ground surface 32,thus preventing damage to the blind 20 from accumulation of liquid. Asecond group of channels 41 is positioned proximal to each window 34,with each channel extending through the sidewall 22 to the interior ofthe blind 20. The sidewall 22 extends beyond the concave exteriorsurface 38 such that the surface is generally not visible to gameresting on the surrounding ground surface 32.

As shown in FIG. 2 and FIG. 2A, the sidewall 22 is comprised of a firstfoam layer 42 having a first indention force deflection (IFD) rating often pounds, and a second foam layer 44 having a second IFD rating of twopounds. Preferably, the foam is a polymer foam. In this embodiment, thethickness of the sidewall 22 is approximately four inches, with thesecond foam layer 44 being thicker than the first foam layer 42.

The sidewall 22, first endwall 35, second endwall 36, and door opening37 define an interior space 46 for isolating an occupant from theenvironment. More specifically, the interior space 46 is defined by thesecond layer 44 of the sidewall 22, a floor surface 48, and the secondendwall 36. A window assembly 50 is associated with each window 34.

Referring to FIGS. 3A & 3B, each window assembly 50 includes a pane 52,pane frame 54 and metallic member 56 that is associated with each of thewindows 34. Each metallic member 56 is generally elongate and positionedproximal to a window 34.

In this embodiment, each pane 52 is one-way glass that allows anoccupant of the blind to see through the pane 52, but impedes game fromseeing movement by the occupant within the interior space. Inalternative embodiments, a semi-transparent decal (e.g., a camouflagewindow decal) may be applied to the panes 52. The frame 54 and sidewall22 define slots on opposing sides of the window 34 that guides the pane52 as it slidably moves to and from a closed position. Channels 41extend through the sidewall 22 and have openings positioned proximal tothe frame 54 to inhibit fluid accumulation in the frame 54.

Each pane 52 is connected to a magnetic member 58 (e.g., a neodymiummagnet) with a length of cordage 60 (e.g., rope, string) that ispositioned through eyebolts 62 or pulleys that are mounted to thesidewall 22. The magnetic member 58 is attracted to the metallic member56 with sufficient strength to resist the force applied to the magneticmember 58 by the weight of the pane 52 transferred through cordage 60.Each pane 52 may be moved between an open and a closed position (andpositions in between) by moving the position of the magnetic member 58to various positions on the associated metallic member 56. When themagnetic member 58 is positioned at or near a first end 64 of themetallic member 56, the pane 52 is held in an open or substantially openposition. When the magnetic member 58 is moved to a position at or nearthe second end 66 of the metallic member 56, the pane 52 moves to theclosed, or a substantially closed, position.

The method of manufacturing the blind described with reference to theprevious figures is a generally a two-step process. First, a master moldis made. Second, the blind 20 is manufactured from the master mold.

Making the master mold comprises the follows steps. First, a subjecttree is identified. The subject tree should have an outer trunk surface(e.g., bark) that will remain intact during the mold-creation process.The bark should be relatively new and supple, as older and/or brittlebark will become inadvertently distressed or removed during later stepsof the mold-making process. Importantly, however, while older, brittlebark will not suffice for the methodology presented herein, a treesection may be too supple to accept the silicone mixture withoutdeformation.

Second, a trunk section of the subject tree is cut. If the subject treehas a natural root flare proximal to the ground surface, the trunksection preferably includes the root flare. The length of the trunksection should be at least equal to the desired maximum exterior heightof the blind. As shown in FIG. 4, the trunk section 72 is preferably cutto have parallel, planar surfaces 74, which may or may not haveirregular profiles depending on the characteristics of the selectedtrunk section 72.

Third, as shown in FIG. 4, a spindle 70 having opposing ends 76 isdisposed through the trunk section 72. Preferably, the spindle 70 isdisposed at a right angle relative to the planar surfaces 74 of thetrunk section 72 and through the center of mass to allow even rotationof the trunk section 72 during later steps of the process. The opposingends 76 of the spindle 70 are supported by elevated rollers 78, whichallows the spindle 70 to turn freely in this position.

Fourth, when the trunk section 72 is in the position shown in FIG. 4 arelease agent is applied to the trunk section 72. A suitable releaseagent repels water, and, for example, is petrol-based. Preferably, therelease agent is vegetable oil, but may be any other suitable agent. Therelease agent is applied to the trunk section 72 with a cloth, brush, orother suitable applicator.

Fifth, while the trunk section 72 is rotated in the position shown inFIG. 4 a first coat of a low viscosity silicone mixture having a highShore value is applied. Preferably, the Shore value is greater than orequal to twenty-eight and the viscosity of thirty-thousand cps. Onesuitable silicone is Model HY628# available from Shenzhen HongyejieTechnology Co., Ltd. of Shenzhen, China.

Fifth, after allowing the first coat to dry, and while the trunk section72 is rotated in the position shown in FIG. 4, a second coat of the lowviscosity silicone mixture used for the first coat is applied.Preferably, the second coat is applied with the same silicone mixture asis applied as the first coat.

Sixth, a coat of a second silicone mixture, which has a higher viscositythan the first silicone mixture, is applied. Preferably, application ofthe second silicone mixture occurs when the trunk section 72 is in avertical position rather than the horizontal position shown in FIG. 4.The second silicone mixture may be derived from the first siliconemixture being combined with a thickening agent and/or a suitableaccelerant to decrease cure time.

Seventh, a layer of barrier material is applied over the second siliconemixture. Preferably, the barrier layer is a cotton fabric, such as acheesecloth, which is a loose-woven gauze-like cotton cloth.

Eighth, a coat of a third silicone mixture is applied over the layer ofbarrier material. Preferably, the third silicone mixture is the same asthe first silicone mixture previously applied.

Ninth, as shown in FIG. 5, attachment members 95 for hanging the mastermold from an overhead support are attached to at least one of thesilicone mixture layers. In the described embodiment, the attachmentmembers 95 are fully immersed in at least one silicone layer. Once thesilicone layers have cured, the attachment members 95 are impeded frommovement relative to the remainder of the master mold 80 and willsupport the weight of the master mold 80 without detaching.

After the steps identified supra are completed, the composite layers ofthe master mold are inspected for defects in the silicone, such as spotsor tears, and patched as needed with the high viscosity siliconemixture.

Still referring to FIG. 5, a seam 81 is formed between the first andsecond ends 84, 86 of the master mold 80, which define opposing seamends 82. Straps or magnets 83 are fused with silicone near the seam ends82 to allow for later reconnection of the seam ends 82. Thereafter, themaster mold 80 is removed from the trunk section (not shown) byseparating the seam ends 82.

Referring to FIG. 6, which shows the master mold 80 with the seam ends82 unconnected, areas proximal to the opposing ends 84, 86 of theinterior surface 88 of the master mold 80 are coated with an elastomer90 (e.g., polyurea) to improve durability. The elastomer coating 90 isapplied along the opposing ends 84, 86 of the master mold 80. Thiselastomer coating 90 hardens these areas to inhibit chipping, breaking,or other damage of the master mold 80.

While the preferred method contemplates applying the silicone mixturesto a trunk section, an alternative embodiment of the method contemplatesa “flat pour.” According to this alternative embodiment, the exteriorsurface of the identified trunk section (i.e., the phellum) is removedand kept intact. Typically, this is done by removing the entire barklayer, which includes the phellum (or cork), the phellogen (or corkcambium), the phelloderm, the cortex, and the phloem.

After completion of the master mold 80, an individual blind may bemanufactured as follows. First, referring back to FIG. 5, the mastermold 80 is hung from overhead supports 93 by chains or ropes 91 to theattachment members 95, and stretched to the desired form using cordage92 connected between the master mold 80 and a support framework 94. Thedesired shape is a generally tree-trunk shaped cylinder having open endsthat is at least substantially similar to the shape of the trunk sectionfrom which the master mold 80 was formed. Once the desired form for themaster mold 80 is obtained, the seam ends 82 are closed by connectingthe magnets 83 or straps.

Thereafter, as shown in FIG. 7, the first foam layer 42 is applied(e.g., sprayed, stamped, poured, etc.) on the inner surface of themaster mold 80. After the first foam layer 42 cures, a door frame 96 isfastened to the first foam layer 42, and foam applied therearound tosecure the door frame 96 in place relative to the first foam layer 42.In this embodiment, the first foam layer 42 has an IFD of ten pounds.One suitable B-side component is a urethane system resin component soldunder the designation High Density Foam 1006 Resin, available fromPolyGreen Solutions, LLC of Atlanta, Ga. This B-side component may becombined with a polymethylene polyphenylisocyanate A-side componentdesignated PM 200, also available from PolyGreen Solutions, LLC.

After the first foam layer 42 has cured, the second foam layer 44 (seeFIG. 2A) is applied to the inner surface of the first foam layer 42. Thesecond foam layer 44 has an IFD of two pounds. One acceptable B-sidefoam component for the second foam layer 44 is a urethane system resincomponent sold under the designation Wall Foam 186 Resin, which isavailable from PolyGreen Solutions, LLC of Atlanta, Ga.

The first and second foam layers 42, 44 together are approximately fourinches thick. After the second foam layer 44 has cured, the master mold80 may be lowered from the overhead supports 93, and the master mold 80separated at the seam 81, leaving behind the blind 20, as shown in FIG.8.

A typical embodiment of a blind has the following specifications: (a)exterior height of eighty-eight inches (b) exterior diameter ofseventy-seven inches (c) an interior height of seventy-eight inches; (d)interior diameter of sixty-seven inches; and (e) a weight of threehundred pounds. Among other advantages, these dimensions allow a bowhunter adequate space to fully draw the string of a typical bow.

The blind also provides sound and temperature insulating benefits aswell. Data shows that the insulating layer of foam provides atemperature differential of +31 degrees (F.) (relative to the exteriorof the blind) in the winter, and −16 degrees (F.) (relative to theexterior) during the summer. The insulating layer foam further inhibitssound transmission from the interior space to the surroundingenvironment.

FIG. 9 shows another embodiment of an apparatus having the features ofthe present invention, which embodiment is a hunting blind 120 thatsimulates the textures and colors of a subject tree's bark. The blind120 comprises a generally trunk-shaped sidewall 122 having an exteriorsurface 124 that imitates the texture of natural tree bark, except thatthe sidewall is not generally-cylindrically shaped. This texture mayinclude bare areas 126 that are smooth, such as are frequently found innature. Such natural textures and shapes generally do not comprisestraight lines and right angles. Although the blind 120 is shown ashaving the bark of an oak tree, any number of different trees may besimulated using the process described herein. The exterior surface 124of the sidewall 122 is coated with UV protective paint that is selectedto imitate the colors of the bark of the subject tree.

The trunk-shaped sidewall 122 includes a first end 128 and a second end130. In the preferred embodiment as intended to be used, the first end128 is positioned proximal to a ground surface 132 and is flared tosimulate the root flare of a natural tree. The second end 130 ispositioned distally from the ground surface 132. A window 134 isdisposed through the sidewall 122 to provide a viewport. Preferably, thewindow 134 is irregularly shaped so as not to use straight lines orright angles.

The present disclosure includes preferred or illustrative embodiments inwhich a specific blind and method of manufacturing are described.Alternative embodiments of such a blind and method can be used incarrying out the invention as claimed and such alternative embodimentsare limited only by the claims themselves. For example, while thespecific embodiments described herein related to hunting blinds, themethod of the present invention may be used for planters, bird feeders,and the like. Moreover, in addition to vegetation, the simulated naturalsurface may include various other surfaces, such as rocks. Other aspectsand advantages of the present invention may be obtained from a study ofthis disclosure and the drawings, along with the appended claims.

I claim:
 1. An apparatus having an exterior surface simulating a surfacefound in nature, the apparatus comprising: a sidewall having a first endand a second end, the sidewall having a first surface simulating anatural surface, the sidewall further having a second surface, whereinthe sidewall defines at least one window extending between the first andsecond surfaces.
 2. The apparatus of claim 1 further comprising: a firstendwall adjacent to the first end of the sidewall, said first endwallhaving a concave exterior surface; a second endwall adjacent to thesecond end of the sidewall; wherein the sidewall, first endwall, andsecond endwall define an interior space; and wherein the sidewall isgenerally-cylindrical.
 3. The apparatus of claim 2 wherein said sidewalldefines a first plurality of channels establishing a fluid communicationpath from the concave exterior surface of the first endwall to firstsurface of the sidewall.
 4. The apparatus of claim 2 wherein saidsidewall defines a second plurality of channels extending through saidsidewall establishing a fluid communication path between the interiorspace and the first surface of the sidewall.
 5. The apparatus of claim 1further comprising a door assembly connected to said sidewall, said doorassembly having a door rotatable to and from a closed position in whichsaid door occupies said door opening, and wherein said door has an outerdoor surface textured to imitate a vegetation surface.
 6. The apparatusof claim 1 further comprising a plurality of panes movable to and from aposition substantially covering one of said at least one window.
 7. Theapparatus of claim 1 further comprising: at least one metallic memberassociated with said at least one windows; and at least one magneticmember attracted to said metallic members.
 8. The apparatus of claim 1wherein the sidewall comprises a first layer of polymer foam having afirst indention force deflection (IFD) rating and a first thickness anda second layer of polymer foam having a second IFD rating that is lessthan the first IFD rating and a second thickness, and wherein thicknessof the second layer is greater than the thickness of the first layer. 9.The apparatus of claim 8 wherein said first IFD rating is ten pounds andsaid second IFD rating is two pounds.